Building construction components

ABSTRACT

A header and jamb stud arrangement that employs connectors for affixing the header assemblies to the jamb studs. The connector may comprise a connection plate that may be provided with a locator tab for locating the plate relative to the header assembly and the jamb stud. The connection plate may be provided with a collection of differently shaped holes which each correspond to a fastener. By installing fasteners through all of one shape of hole, a first load capacity can be achieved. By installing fasteners through other shapes of fastener holes, other load capacities may be achieved. Different embodiments of header assemblies are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part application of U.S. patentapplication Ser. No. 10/981,868, entitled Building ConstructionComponents, filed Nov. 5, 2004, the disclosure of which is hereinincorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to building construction components and, moreparticularly, to building construction components fabricated from metalsuch as headers, sills, trusses, girders and support posts.

2. Description of the Invention Background

Traditionally, the material of choice for new residential and commercialbuilding framing construction has been wood. However, over the years,the rising costs of lumber and labor required to install wood framingcomponents have placed the dream of owning a newly constructed home outof the economic reach of many families. Likewise such increasing costshave contributed to the slowing of the development and advancement ofurban renewal plans in many cities. Other problems such as thesusceptibility to fire and insect damage, rotting, etc. are commonlyassociated with wood building products.

In view of the foregoing problems and shortcomings of wood construction,steel is rapidly gaining acceptance among homebuilders and homeownersalike due to is cost effectiveness, dimensional stability,noncombustibility, insect resistance, durability, highstrength-to-weight ratio and recycleability. These advantages have longbeen recognized by the commercial construction industry wherein steelhas been the material of choice for several decades.

Regardless of whether a building comprises a multistory commercialstructure or a single story residence, C-shaped metal studs and tracksare commonly used in their construction. FIG. 1 illustrates aconventional C-shaped metal stud 10 that has a web 12 and a pair offlanges 14. A lip 16 is also formed on the end of each flange 14 tofurther strengthen the stud. Such studs 10 are commonly fabricated fromcold-formed steel utilizing conventional rollforming techniques.Similarly, the conventional tracks 20 that are employed by the buildingtrades each have a web 22 and a pair of flanges 24. The tracks 20 aresimilar in construction as the C-shaped studs, but lack the lack thelips that are commonly formed on the ends of the stud flanges. See FIG.2.

In most construction applications, walls are constructed by attaching aseries of C-shaped studs between a top track and a bottom track. Thebottom track is usually attached to the floor structure by screws orother fasteners and the top track is usually attached to the ceilingjoists. The ends of the studs are inserted into the top and bottomtracks and are attached thereto by screws, welds, etc. After the wallframe is constructed, then the desired wallboard material is attached tothe flanges of the studs and tracks utilizing screws or other fastenersto complete the wall assembly.

In those walls that require door and/or window openings to be framedtherein, a header is constructed to transfer loads occurring above theopening to the vertically extending studs adjacent the opening. Thestuds that define the vertical boundaries of the opening are oftenreferred to as the “jamb” studs. FIGS. 3-5 illustrate one prior headerand jamb stud arrangement that is formed utilizing conventional C-shapedstuds and tracks. As can be seen in FIGS. 3 and 4, the header 30 isformed by attaching a first C-shaped stud 32 to a track 40 such that theflanges 36 of the stud 32 are received between the flanges 42 of thetrack 40. A second upwardly facing piece of track 46 is then attached tothe web 34 of the first stud 32. Such header 30 is commonly fabricatedby attaching these components together with fasteners such as screws 49or the like. The use of such screws, however, creates undesirablebuildups which can lead to drywall finishing problems. In thealternative, the components may be welded together which adds toassembly time and expense.

Likewise, the jamb studs 50 are each commonly formed by attaching aC-shaped stud 52 to another piece of track 60 such that the flanges 56of the stud 52 are received between the flanges 64 of the track 60 andthen attaching the web 72 of another stud 70 to the web 64 of the track60. These components are also commonly coupled together with screws 49which can lead to drywall finishing problems. In the alternative, theymay be welded together to form the jamb stud 50. Such assembly approachrequires additional skilled labor. These combinations of components havebeen found to provide the jamb stud with a sufficient amount of strengthto receive the loads from the header without failing or buckling.

To complete the header assembly, the header 30 is then attached to eachjamb stud 50 by corresponding L-shaped clips 80. The clips 80 are weldedor screwed to each jamb stud 50. In addition, sections of studs 82 areattached between the track 60 and the section of upper track (not shown)to which the upper ends of the jamb studs 50 are attached. Such studsegments 82 are often referred to in the industry as “cripple studs” andfurther transfer loads from the upper structures to the header.

FIG. 6 illustrates a prior truss chord 90 that is fabricated utilizingconventional C-shaped studs. By way of background, trusses are used toform the support frame for a roof or, in some applications, are used toform the support for an upper floor. The upper and lower portions of thetruss are known as the “chords” and the members that extend between thechords are called “webs”. As can be seen in FIG. 6, a typical methodemployed to form a truss chord 90 is to weld two C-shaped studs 92together as shown. The truss webs are formed from other pieces ofC-shaped studs 94 that are fastened to the chord 90 by screws, boltsetc. This arrangement, however, is labor intensive because studs have tobe welded together to form the necessary chords.

Conventional C-shaped studs and tracks are also used to form supportposts for supporting loads from the structures located above the posts.FIG. 7 illustrates a prior method of constructing a support post. As canbe seen in that Figure, a total of 3 C-shaped studs 102 and two tracks104 are employed. The studs 102 and tracks 104 may be connected togetherby a collection of screws or by welding. Both fastening methods,however, are time consuming and attribute to higher labor costsassociated with their fabrication.

Floors are also constructed utilizing components that are somewhatidentical to C-shaped studs and tracks utilized to form the wall framesfor the structure. However, the tracks and C-shaped members used to formthe floor structure can be larger than those like-shaped components usedto form wall structures. The floor of a structure is commonly formedfrom a series of C-shaped members that span the distance between supportstructures or support walls. These C-shaped members are commonlyreferred to as floor joists. The ends of the joists are coupled totracks referred to as joist rims that are either supported on a wall orother structure by one of their flanges or have their webs attached tothe wall or structure. The joists are commonly attached to the joistrims by conventional L-shaped clips or by tabs that are integrallyformed in the web of the joist rim.

In those instances wherein the span is too long or loading conditionsrequire it, beams known as girders are employed. The girders serve aspoints of attachments for the ends of adjacent floor joists as shown inFIG. 8. In the past, many floor girders 110 were fabricated utilizing aconventional stud 112 nested in a conventional track 118. The flanges ofthe track 118 and stud 112 were attached together utilizing screws 119or welds. The floor joists 120 were then attached to the girder 110 bymeans of L-shaped clips 122 and screws. Such approach required extralabor to assembly the girders. In addition, when screws are used toassemble the girder, the screws cause the flooring material to be raisedup or bulge in the area around each screw head.

FIG. 8A illustrates a prior method of constructing a load bearing headerarrangement. As can be seen in that Figure, the header 130 was formedfrom two conventional studs or C-shaped members 140 that were retainedin spaced-apart relationship relative to each other between a piece ofupper track 150 and a piece of lower track 160. The pieces are heldtogether by a collection of screws 162 or by welding. Both fasteningmethods, however, are undesirably time consuming.

Thus, as can be appreciated from the forgoing discussion, a variety ofdifferent components utilized in constructing residential and commercialbuildings from steel are fabricated from conventional C-shaped studs andtracks. While the use of such components affords a host of advantagesover the use of wood beams and the like, the added labor and materialsrequired to fabricate such components undesirably lead to increasedconstruction costs.

SUMMARY

In accordance with one embodiment of the present invention, there isprovided a header assembly that includes a first header stud thatcomprises a substantially planar first header web and a first headerflange that protrudes from the substantially planar first header web. Asecond header flange protrudes from the substantially planar firstheader web and is spaced from the first header flange. A first headerleg protrudes from the first header flange and is substantially parallelto the substantially planar first header web. A second header legprotrudes from the second header flange and is substantially parallel tothe substantially planar first header web and is substantially coplanarwith the first header leg. A first header return is provided on an endof the first header leg and a second header return is provided on an endof the second header leg. This embodiment of the present invention alsoincludes another header stud that includes another substantially planarheader web and another first header flange that protrudes from theanother substantially planar header web. Another second header flangeprotrudes from the another substantially planar header web and is spacedfrom the another first header flange. Another first header leg protrudesfrom the another first header flange and is substantially parallel tothe another substantially planar header web. Another second header legprotrudes from the another second header flange and is substantiallyparallel to the another substantially planar header web and issubstantially coplanar with the another first header leg. Thisembodiment further includes another first header return on another endof the another first header leg and another second header return onanother end of the another second header leg. The another header stud isretained in abutting contact with the first header stud to form a headerassembly.

Yet another embodiment of the present invention is directed to aconnector for coupling an end of a header assembly to a jamb stud thatis oriented adjacent thereto. In one embodiment, the connector comprisesa substantially planar connection plate sized to span between the end ofthe header assembly and the jamb stud. A plurality of first fastenerholes are provided through the connection plate. The first fastenerholes each have a first shape. A plurality of second fastener holes areprovided through the connection plate. Each of the second fastener holeshas a second shape that differs from the first shape. A locator tabprotrudes from the substantially planar connection plate such that whenthe locator tab is brought into abutting contact with the jamb stud, aportion of the end of the header assembly is coextensive with a firstportion of the connection plate and a portion of the jamb stud iscoextensive with a second portion of the connection plate such that atleast one first fastener hole and at least one second fastener hole areeach adjacent to the coextensive end of the header assembly and at leastone other first fastener hole and at least one other second fastenerhole are adjacent to the coextensive portion of the jamb stud.

Another embodiment of the present invention comprises a header and jambstud arrangement that includes a pair of jamb studs spaced from eachother and a header assembly that extends between the jamb studs todefine an opening therebetween. The header assembly comprises asubstantially planar first header web and a first header flange thatprotrudes from the substantially planar first header web. A secondheader flange protrudes from the substantially planar first header weband is spaced from the first header flange. A first header leg protrudesfrom the first header flange and is substantially parallel to thesubstantially planar first header web. A second header leg protrudesfrom the second header flange and is substantially parallel to thesubstantially planar first header web and is substantially coplanar withthe first header leg. A first header return is provided on an end of thefirst header leg and a second header return is provided on an end of thesecond header leg. This embodiment of the present invention furthercomprises another header stud that includes another substantially planarheader web and another first header flange that protrudes from theanother substantially planar header web. Another second header flangeprotrudes from the another substantially planar header web and is spacedfrom the another first header flange. Another first header leg protrudesfrom the another first header flange and is substantially parallel tothe another substantially planar header web. Another second header legprotrudes from the another second header flange and is substantiallyparallel to the another substantially planar header web and issubstantially coplanar with the another first header leg. Another firstheader return is provided on another end of said another first headerleg and another second header return is provided on another end of theanother second header leg, The another header stud is in abuttingcontact with the first header stud to form a header assembly. A firstconnector arrangement is provided for connecting one end of the headerassembly to one of the jamb studs and a second connector arrangement isprovided for connecting another end of the header assembly to the otherone of said jamb studs.

Another embodiment of the present invention comprises a header and jambstud arrangement that includes a pair of jamb studs spaced from eachother and a header assembly that extends between the pair of spaced jambstuds to define an opening between the jamb studs. A first connectorarrangement for connecting one end of said header assembly to one ofsaid jamb studs is provided. In one embodiment, the first connectorarrangement comprises a pair of first connectors wherein at least onefirst connector comprises a substantially planar first connection platesized to span between the end of the header assembly and the jamb stud.A plurality of first fastener holes are provided through the firstconnection plate wherein the first fastener holes each have a firstshape. This embodiment further includes a plurality of second fastenerholes through the first connection plate, wherein each of the secondfastener holes has a second shape that differs from the first shape. Afirst locator tab protrudes from the substantially planar firstconnection plate such that when the locator tab is brought into abuttingcontact with the jamb stud, a portion of the end of the header assemblyis coextensive with a first portion of the first connection plate and aportion of the jamb stud is coextensive with a second portion of thefirst connection plate such that it least one first fastener hole and atleast one second fastener hole are each adjacent to the coextensive endof the header assembly and at least one other first fastener hole and atleast one other second fastener hole are adjacent to the coextensiveportion of the jamb stud. A second connector arrangement is provided forconnecting another end of the header assembly to the other one of saidjamb studs.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying Figures, there are shown present embodiments of theinvention wherein like reference numerals are employed to designate likeparts and wherein:

FIG. 1 is a perspective view of a prior art C-shaped stud;

FIG. 2 is a perspective view of a prior art track;

FIG. 3 is a partial perspective view of a prior header and jamb studarrangement;

FIG. 4 is a partial end view of the prior header arrangement depicted inFIG. 3;

FIG. 5 is a partial end of the prior jamb stud arrangement depicted inFIG. 3;

FIG. 6 is a partial perspective view of a prior truss chord assembly;

FIG. 7 is a partial perspective view of a prior art post arrangement;

FIG. 8 is a partial perspective view of a prior floor girder and floorjoist arrangement;

FIG. 8A is a perspective view of a portion of a prior header assembly;

FIG. 9 is an elevational view of a wall frame that employs a headerembodiment, a sill embodiment and a jamb stud embodiment of the presentinvention;

FIG. 10 is an end view of a stud embodiment of the present invention;

FIG. 11 is a perspective view of a portion of a header and jamb studembodiment of the present invention;

FIG. 11 A is a perspective view of the header and jamb stud embodimentdepicted in FIG. 11 with a conventional stud attached to the jamb stud;

FIG. 12 is a partial cross-section view of the header and jamb studembodiment of the FIG. 11 taken along line 12-12 in FIG. 11;

FIG. 13 is a perspective view of one embodiment of an attachment clip ofthe present invention;

FIG. 14 is a partial cross-sectional view of the sill and jamb studembodiment of FIG. 9 taken along line 14-14 in FIG. 9;

FIG. 15 is a partial perspective view of another header and jamb studembodiment of the present invention;

FIG. 16 is a perspective view of another attachment clip of the presentinvention;

FIG. 17 is a perspective view of a portion of a truss chord embodimentof the present invention;

FIG. 18 is a perspective view of a portion of a truss embodiment of thepresent invention;

FIG. 19 is a perspective view of a portion of a support post of thepresent invention;

FIG. 20 is a portion of a cross-sectional view of the support postembodiment of FIG. 19 taken along line 20-20 in FIG. 19;

FIG. 21 is a perspective view of a portion of a floor girder embodimentof the present invention;

FIG. 22 is an end view of another stud embodiment of the presentinvention;

FIG. 23 is a perspective view of a portion of the stud of FIG. 22;

FIG. 24 is a perspective view of a portion of other stud embodiments ofthe present invention;

FIG. 25 is a perspective view of a portion of a conventional headerassembly attached to a portion of a conventional jamb stud assemblyutilizing a pair of connection plates of one embodiment of the presentinvention;

FIG. 26 is a perspective view of one embodiment of a connection plate ofthe present invention;

FIG. 27 is a plan view of a squared-shaped hole through the connectionplate depicted in FIG. 26;

FIG. 28 is a plan view of a triangular-shaped hole through the connectorplate of FIG. 26;

FIG. 29 is a cross-section al view of the header assembly and jamb studarrangement depicted in FIG. 25 taken along lines 29-29 in FIG. 25;

FIG. 30 is a perspective view of a portion of one embodiment of a headerassembly of the present invention attached to a portion of aconventional jamb stud assembly utilizing a pair of connection plates ofone embodiment of the present invention;

FIG. 31 is a cross-sectional view of the header assembly depicted inFIG. 30 taken along line 31-31 in FIG. 30;

FIG. 32 is a perspective view of a portion of one embodiment of anotherheader assembly of the present invention attached to a portion of aconventional jamb stud assembly utilizing a pair of connection plates ofone embodiment of the present invention;

FIG. 33 is a cross-sectional view of the header assembly depicted inFIG. 32 taken along line 33-33 in FIG. 32;

FIG. 34 is a perspective view of a portion of one embodiment of anotherheader assembly of the present invention attached to a portion of aconventional jamb stud assembly utilizing a pair of connection plates ofone embodiment of the present invention;

FIG. 35 is a cross-sectional view of the header assembly depicted inFIG. 34 taken along line 35-35 in FIG. 34;

FIG. 36 is a perspective view of a portion of one embodiment of a headerassembly of the present invention attached to a portion of a jamb studof the present invention utilizing a pair of connection plates of oneembodiment of the present invention;

FIG. 37 is a cross-sectional view of the header assembly depicted inFIG. 36 taken along line 37-37 in FIG. 36;

FIG. 38 is a perspective view of a portion of one embodiment of anotherheader assembly of the present invention attached to a portion of a jambstud of the present invention utilizing a pair of connection plates ofone embodiment of the present invention;

FIG. 39 is a cross-sectional view of the header assembly depicted inFIG. 38 taken along line 39-39 in FIG. 38;

FIG. 40 is a perspective view of a portion of one embodiment of anotherheader assembly of the present invention attached to a portion of a jambstud of the present invention utilizing a pair of connection plates ofone embodiment of the present invention; and

FIG. 41 is a cross-sectional view of the header assembly depicted inFIG. 40 taken along line 41-41 in FIG. 40.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings for the purposes of illustrating thepresent embodiments of the invention only and not for the purposes oflimiting the same, FIGS. 9, 11 and 12 illustrate one embodiment of aheader assembly 219 of the present invention utilized to form a windowopening 201 in a wall frame structure 200. As can be seen in FIG. 9, thewall frame structure 200 may be fabricated from a lower track 202 and anupper track 206. The lower track has a web 203 and a pair of upstandingflanges 204. Similarly, the upper track 206 has a web 207 and a pair offlanges 208. A plurality of studs 210 are connected between the lowertrack 202 and the upper track 206 utilizing screws or other suitablefastening methods. The studs 210 are conventional in nature and have aweb 211, a pair of flanges 212 and a lip formed on the end of eachflange 212.

In this embodiment, the header assembly 219 is formed from a uniquelyshaped header stud 220, on embodiment of which is depicted in FIG. 10.As can be seen in FIG. 10, stud 220 includes a substantially planarheader web 222, a first header flange 224 and a second header flange226. The first and second header flanges (224, 226) protrude outwardlyfrom the substantially planar header web 222. A first header leg 228protrudes from the first header flange 224 such that the first headerleg 228 is substantially parallel to the substantially planar header web222. Likewise, a second header leg 230 protrudes from the second headerflange 226 such that it is substantially parallel to the substantiallyplanar header web 222. A first header return 232 protrudes from thefirst header leg 228 and a second header return 234 protrudes from thesecond header leg 230.

In one embodiment, the stud 220 is rollformed from steel sheet byutilizing conventional rollforming methods and equipment. For example,the stud 220 may be fabricated from 12, 14, 16, 18, 20, etc. gage steelor other metal or material. Although the size of the stud 220 and thematerial from which it is formed may vary depending upon the applicationand loading conditions, in one embodiment for example, the web 222 maybe made in various widths of, for example, 3⅝ inches, 6 inches and eightinches (distance “A”). The first and second flanges (224, 226) may befabricated with a variety of different heights ranging from, forexample, 2 inches-3.5 inches (distance “B”). The widths of the first andsecond legs (228, 230) of a stud that has a web width of 3⅝ inches maybe 1 1/16 inches (distance “C”). Thus in this embodiment, the distancebetween the ends of the first and second legs (228, 230) is 1½ inches(distance “D”). The widths of the first and second legs (228, 230) of astud that has a web width of six inches would be, for example, 2¼inches. The widths of the first and second legs (228, 230) of a studthat has a web width of eight inches would be, for example, 3¼ inches.In various embodiments, the length of each return portion (232, 234) maybe ¾ inches (distance “E”). It will be appreciated, however, that othersizes of stud 220 could be used depending upon the specific application.

In the embodiment depicted in FIGS. 9 and 11, a header stud 220 is usedto form the header assembly 219 and studs 220′ are used to form the jambstuds which form the vertical boundaries of the opening 201. Studs 220′are identical to studs 220 and are identified herein with the “′” symbolto distinguish between the use of a stud 220 as a header and as a jambstud. For example, each jamb stud 220′ has a substantially planar jambstud web 222′, a first jamb stud flange 224′ and a second jamb studflange 226′ that protrude from the jamb stud web 222′. A first jamb studleg 228′ is attached or otherwise formed on the first jamb stud flange224′ and a second jamb stud leg 230′ is formed on or attached to thesecond jamb stud flange 226′. A first jamb stud return 232′ is formed onthe end of the first jamb stud leg 228′ and a second jamb stud return234′ is formed on the end of the second jamb stud leg 230′. See FIG. 11.In this embodiment, the stud 220 is interposed between the jambs studs220 and may be quickly coupled to the jambs studs 220′ by connectorclips 240.

As can be seen in FIG. 13, in this embodiment, on connector clipembodiment has a clip web 242 and a pair of clip flanges 244 protrudingfrom the clip web 242. The clip flanges 244 define a header-receivingspace 245 therebetween. The clip web 242 of the clip 240 is fastened tothe jamb stud web 222′ of the corresponding jamb stud 220′ byappropriately sized fasteners such as sheet metal screws or the like andone end of the header stud 220 is inserted between the clip flanges 242as shown in FIG. 11. Each end of the header stud 220 is attached to theclip 240 utilizing threaded fasteners 246 such as sheet metal screws orthe like. However, header stud 220 could be welded to the clip 240.

As shown in FIG. 11, in this embodiment, a header track 260 is supportedon and attached to the first and second legs (228, 230) of the headerstud 220. Header track 260 has a header track web 262 and a pair ofupstanding header track flanges 264. The web 262 of the header track 260is attached to the first and second header legs (228, 230) of the headerstud 220 by fasteners 246 which may comprise conventional sheet metalscrews or the like. In addition, pieces of studs 270, which may beconventional in nature, may be attached to the track header 260 and theupper track 206. Studs 270 may each have a web 272, pair of flanges 274and a return 276 formed on the end of each flange 274. The flanges 274of the studs 270 are attached to the header flanges 264 and the uppertrack flanges 208 by fasteners such as sheet metal screws or the like.Studs 270 serve as the cripple studs for the header arrangement. Forwindow or door openings that require additional support due to theirwidth, an additional conventional stud 210 could be attached to the jambstud 220′ as shown in FIG. 11A.

As can also be seen in FIGS. 9 and 14, sill studs 220″ may be used toform a windowsill designated as 280. Sill studs 220″ are identical toheader studs 220 and are identified herein with the ″ symbol todistinguish between the use of a stud 220 as a header and as a sillstud. For example, each sill stud 220″ has a substantially planar jambstud web 222″, a first sill stud flange 224″ and a second sill studflange 226″ that protrude from the sill stud web 222″. See FIG. 14. Afirst sill stud leg 228″ is attached or otherwise formed on the firstsill stud flange 224″ and a second sill stud leg 230″ is formed on orattached to the second sill stud flange 226″. A first sill stud return232″ is formed on the end of the first sill stud leg 228″ and a secondsill stud return 234″ is formed on the end of the second jamb stud leg230′.

In this embodiment, the sill stud 220″ is oriented with the flanges 224″and 226″ extending toward the lower track 202 and is coupled to the jambstuds 220′ by connector clips 240 in the manner described above. Also inthis embodiment, a sill track 260″ is supported on and attached to thefirst and second legs (228″, 230″) of the sill stud 220″. Sill track260″ has a sill track web 262″ and a pair of upstanding sill trackflanges 264″. The sill track web 262″ of the sill track 260″ is attachedto the first and second sill track legs (228″, 230″) of the sill stud220″ by fasteners 246″ which may comprise conventional sheet metalscrews or the like. In addition, pieces of studs 270″, which may beconventional in nature, may be attached to the sill track 260″ and thelower track 202. Studs 270″ may each have a web 272″, pair of flanges274″ and a return 276″ formed on the end of each flange 274″. Theflanges 274″ of the studs 270″ are attached to the sill track flanges264″ and the lower track flanges 208 by fasteners 246″ such as sheetmetal screws or the like. Studs 270″ serve as the cripple studs for thesill 280.

Such header, jamb stud and sill arrangements of the present inventionrequire less labor and material to assemble than the prior headerconfigurations. It will also be appreciated, however, that the uniquelyshaped studs 220, 220′, 220″ could be used in a variety of otherapplications and combinations. For example, the header studs 220′ andthe sill studs 220″ could be used to form headers and sills,respectively as described above in connection with conventional jambstud arrangements. Likewise, the studs 220′ could be used to form jambstuds that are used in connection with conventional header and sillassemblies. Thus, it will be appreciated that the header studs 220and/or sill studs 220″ do not have to be used in connection with jambstuds 220′ if use of other jambs stud arrangements is more preferableand visa-versa. It will be also appreciated that the studs (220, 220′,220″) could be used in connection with wood studs and wood framingassemblies.

In another header assembly embodiment of the present invention, aconnector clip 290 of the type illustrated in FIGS. 15 and 16 isemployed. As can be seen in FIG. 16, the connector clip 290 has a pairof clip attachment tabs 292 and a raised central portion 296. The clipattachment tabs 292 are substantially coplanar with each other. Thecentral portion 296 is substantially parallel to the clip attachmenttabs 292 and is attached thereto by a pair of clip legs 294. The clipattachment tabs 292 are attached to the jamb stud web 222′ of the jambstud 220′ by fasteners 299 such as sheet metal screws and the end of theheader stud 220 is inserted over the central portion 296 such that thecentral portion 296 is received in the area between the first and secondheader flanges (224, 226) and the first and header second legs (228,230). As can be seen in FIGS. 15 and 16, a pair of return-receivingslots 298 are provided in a portion of the central portion 296 and oneof the clip legs 294 for receiving the first and second header returns(232, 234) when the ends of the header stud 220 is inserted over theraised central portion 286. The header stud 220 is then attached to theconnector clip 290 by conventional fasteners such as such metal screwsor the like. The header stud 220 could also be attached to the connectorby welding or other fastener arrangements. Such connector cliparrangement may provide further torsional stability to the header stud220 when installed in this manner. Connector 290 could also be used toattach the sill studs 220″ to the jamb studs 220′ in the above-describedmanners.

FIG. 17 illustrates a unique and novel truss chord arrangement 300 ofone embodiment of the present invention. In this embodiment, a chordstud 310, which is essentially identical in construction as the headerstud 220, is employed to form the truss chord. The chord stud 310 has asubstantially planar chord web 312 and a first chord flange 314 and asecond chord flange 316 protruding therefrom. A first chord leg 318protrudes from the first chord flange 314 and a second chord leg 320protrudes from the second chord flange 316. A first chord return 322 isformed on the end of the first chord leg 318 and a second chord return324 is formed on the end of the second chord leg 320. Pieces of studs330 which are conventional in nature are attached to the first andsecond chord legs (314, 316) and the chord web 312 of the chord stud 310utilizing fasteners 340 such as sheet metal screws. The studs 330 eachhave a web 332, a pair of flanges 334 and a lip 336 formed on the end ofeach flange 334. These studs 330 form the webs of the truss. Sucharrangement eliminates labor required to weld two pieces of studtogether to form the truss chord.

FIG. 18 illustrates another truss assembly 300′ of the presentinvention. In this embodiment, the truss webs are formed from trussstuds 310′ which are each essentially identical in construction as thechord stud 310. Each truss stud 310′ has a substantially planar chordweb 312′ and a first chord flange 314′ and a second chord flange 316′protruding therefrom. A first chord leg 318′ protrudes from the firstchord flange 314′ and a second chord leg 320′ protrudes from the secondchord flange 316′. A first chord return 322′ is formed on the end of thefirst chord leg 318′ and a second chord return 324′ is formed on the endof the second chord leg 320′. In this embodiment, the truss studs 310″are attached to the chord stud 310 by one or more gusset plates 350′ andfasteners 354′ such as sheet metal screws. The gusset plates 350′ may befabricated from steel or other suitable material.

FIGS. 19 and 20 illustrate a support post 400 embodiment of the presentinvention that is formed utilizing a post stud 410 which is identical tothe header stud 220 described above. The post stud 410 has asubstantially planar post stud web 412 and a first post stud flange 414and a second post stud flange 416 protruding from the post stud web 412.A first post stud leg 416 protrudes from the first post stud flange 414and a second post stud leg 420 protrudes from the second post studflange 416. A first post stud return 422 is formed on the end of thefirst post stud leg 416 and a second post stud return 424 is formed onthe end of the second post stud leg 420. See FIG. 19.

In this embodiment, the post stud 410 is used in connection with twostuds 430. The studs 430 each have a web 432 and two flanges 434. A lip436 is formed on the end of each flange 434. The post 400 is formed byattaching the web 432 of one of the studs 430 to the post stud 412 ofthe stud post stud 410 with fasteners 438 such as sheet metal screws orthe like and the web 432 of the other stud 430 is attached to the firstand second post stud legs (418, 420) of the post stud 410 by sheet metalscrews 438 or the like. I have discovered that such arrangement providesan equivalent amount of structural support as prior post arrangementsthat employ three conventional studs and two pieces of conventionaltrack. Thus, this embodiment of the present invention reduces the amountof material needed and also the amount of labor needed to assemble itwhen compared to prior post assemblies. It will be appreciated, however,that the post stud 410 may also be used in connection with one stud 430or more than two studs 430 without departing from the spirit and scopeof the present invention.

The unique and novel studs of the present invention may also be used asa floor girder 502 in a floor system 500. More particularly and withreference to FIG. 21, a single girder stud 510 serves as a floor girderfor attaching conventional floor joists 520 thereto. The girder stud 510is identical in construction when compared to the header stud 220described above. In one embodiment, the girder stud 510 has asubstantially planar girder web 512 and a first girder flange 514 and asecond girder flange 516 protruding from the girder web 512. A firstgirder leg 518 protrudes from the first girder flange 514 and a secondgirder leg 520 protrudes from the second girder flange 516. A firstgirder return 522 is formed on the end of the first girder leg 518 and asecond girder return 524 is formed on the end of the second girder leg520.

The floor joists 530 may have a joist web 532 and a first joist flange534 and a second joist flange 536. A first joist lip 538 is formed onthe end of the first joist flange 534 and a second joist lip 540 isformed on the end of the second joist flange 536. One series of joists530 are attached to the first and second girder legs (518, 520) of thegirder stud 510 by conventional L-shaped clips 550 and sheet metalscrews 552 or the like. The joists 530 protruding from the other side ofthe girder stud 510 are attached to the girder web 512 of the girderstud 510 by L-shaped clips 550 and fasteners 552. Such improvedarrangement eliminates the need to assemble the girder from aconventional stud and track and the labor associated with making suchgirder. It will be further appreciated that the girder of the presentinvention may find utility in non-floor applications without departingform the spirit and scope of the present invention.

FIGS. 22 and 23 illustrate an alternative stud embodiment 620 of thepresent invention. Stud 620 includes a web 622, a first flange 624 and asecond flange 626. The first and second flanges (624, 626) protrudeoutwardly from the web 622. A first leg 628 protrudes from the firstflange 624 such that the first leg 628 is substantially parallel to theweb 622. Likewise, a second leg 630 protrudes from the second flange 626such that it is substantially parallel to the web 622. A first return632 protrudes from the first leg 628 and a second header return 634protrudes from the second header leg 630. See FIG. 22.

In one embodiment, the stud 620 is rollformed from steel sheet byutilizing conventional rollforming methods and equipment. For example,the stud 620 may be fabricated from 12, 14, 16, 18, 20, etc. gage steelor other metal or material. In this embodiment, the stud 620 may furtherinclude a series of stiffener ribs. More particularly and with referenceto FIG. 22, the web 622 may have one or more web stiffener ribs 623therein. Web stiffener ribs 623 may continuously extend the entirelength of the web 622 or they may, for example, be provided in anintermittent manner along the web 622. Similarly, flange stiffener ribsmay be provided in the flanges 624 and/or 626. For example, at least onefirst flange stiffener rib 625 may be provided in the first flange 624.The first flange stiffener rib 625 may continuously extend the entirelength of the first flange 624 or it may be intermittently providedtherein. At least one second flange stiffener rib 627 may be provided inthe second flange 626. The second flange stiffener rib 627 may extendthe entire length of the second flange 626 or it may be intermittentlyprovided therein. In addition, at least one first leg stiffener rib 629may be provided in the first leg 628. The first leg stiffener rib 629may continuously extend the entire length of the first leg 628 or it maybe intermittently provided therein. At least one second leg stiffenerrib 631 may be provided in the second leg 630. The second leg stiffenerrib 631 may extend the entire length of the second leg 630 or it may beintermittently provided therein. Various stud embodiments may includeone or more web stiffener ribs, flange stiffener ribs and leg stiffenerribs or any combination thereof depending upon the specific application.For example, one embodiment may only include at least one stiffener ribin the web of the stud. Another embodiment may only include at leas onestiffener rib in each flange. Another embodiment may include at leastone stiffener rib in each of the legs. Still another embodiment mayinclude at least one stiffener rib in the flanges, but not in the web.Another embodiment may include at least one stiffener rib in each leg,but nowhere else in the stud. Another embodiment may include at leastone stiffener rib in each leg and at least one stiffener rib in the web,but not in the flanges. The present disclosure is meant to encompass allpermutations and combinations of stiffener ribs without departing fromthe spirit and scope of the present invention.

In yet another embodiment, one or more access holes 700 may be providedthrough the webs of studs 220, 220′, 220″, 620 disclosed herein. SeeFIG. 24. The access holes may be formed in the webs of the respectivestuds such that a flange 702 extends around the perimeter of the hole700. Studs containing such holes could be used in any of theabove-described embodiments to form, for example, headers, sills, jambstuds, truss chords, posts, and girders.

FIG. 25 illustrates a portion of a lintel arrangement 800 that is spacedbetween conventional jamb studs 50 of the type and constructiondescribed above to form the top of a door or window opening 804. As wasdescribed above, the jamb studs 50 are each commonly formed by attachinga C-shaped stud 52 to another piece of track 60 such that the flanges 56of the stud 52 are received between the flanges 64 of the track 60 andthen attaching the web 72 of another stud 70 to the web 64 of the track60. These components are also commonly coupled together with screws 49or, in the alternative, they may be welded together to form the jambstud 50. This embodiment employs unique and novel connectors 810 tofasten a conventional header 130 of the type and construction depictedin FIG. 8A to the jamb studs 50.

As described above, the conventional header 130 is formed from twoconventional studs or C-shaped members 140 that are retained inspaced-apart relationship relative to each other between a piece ofupper track 150 and a piece of lower track 160. The pieces are heldtogether by a collection of screws 162 or by welding.

One embodiment of the unique and novel connectors 810 of the presentinvention is depicted in FIG. 26. As can be seen in that Figure, theconnector 810 comprises a substantially planar connection plate 812 thatis fabricated from suitable material that is capable of withstanding theanticipated loading conditions in accordance with the relevant buildingcodes and design requirements. For example, the connection plate 812 maybe fabricated from 12, 14 or 16 gauge metal or other suitable material.In one embodiment, the connection plate 812 is substantially rectangularin shape. For example, in the embodiment depicted in FIG. 26, the plate812 may be approximately 8.5 inches long (distance “F”) andapproximately 6 inches high (distance “G”). However, other plate sizesmay be employed.

The connection plate 812 may be provided with a collection of fastenerholes collectively designated as 820. In one embodiment, the holes 820may all have the same dimensions and shape. For example, the holes 820may all be round and sized to accommodate the appropriate size offastener. In alternative embodiments. If different sizes of fastenersare desirable, the holes may have like shapes by have different sizes toaccommodate different sizes of fasteners.

In the embodiment depicted in FIG. 26, however, a unique and novelfastener hole arrangement is employed. In one embodiment, at least twodifferent shapes of holes are employed. In the embodiment depicted inFIG. 26, for example, three different shapes of holes are employed. Ascan be seen in FIG. 26, two rows 830, 832 of linearly aligned firstholes 834 are provided through the connection plate 812. Row 830 offirst holes 834 is adjacent the upper edge 814 of the connection plate812. In this embodiment, the distance from the upper edge 814 to thecenterlines of the holes 834 in row 830 is approximately 0.5 inches(distance “K”). Row 832 of first holes 834 is adjacent the lower edge816 of the connection plate 812. In this embodiment, the distance fromthe lower edge 816 to the centerlines of the first holes 834 in the row832 is approximately 0.5 inches (distance “L”). As can be seen in FIGS.26 and 27, the first holes 834 are square-shaped. The square-shapedfirst holes 834 are sized to accommodate the desired fasteners that areto be installed through those holes. For example, the square-shapedfirst holes 834 may be approximately 3/32 inch square (distance “M” inFIG. 27) to accommodate No. 10-16 screws. However other sizes and typesof fasteners may be employed

Also in this embodiment, a collection of second holes 844 are providedthrough connection plate 812. Second holes 844 each have a second shapethat differs from the shape of the first holes 834. More particularly inthis embodiment, rows 840, 842 of linearly aligned second holes 844 areprovided through the connection plate 812 in the locations shown in FIG.26. That is, row 840 is adjacent to the row 830 and row 842 is adjacentto row 832. In this embodiment, the centerlines of the second holes 844in the row 840 are spaced approximately 1.0 inches from the centerlinesof the first holes 834 in the row 830. Likewise, the centerlines of thesecond holes 844 in the row 842 are approximately 1.0 inches from thecenterlines of the first holes 834 in row 832. In this embodiment, thesecond holes 844 are triangular-shaped and sized to accommodate thedesired fasteners. In one embodiment, the sides of the second holes 844may be approximately ⅛ inch long (distance “N” in FIG. 28) toaccommodate No. 10-16 screws. However other types and sizes of fastenersmay be employed.

As can also be seen in FIG. 26, in this embodiment, two rows 850, 852 oflinearly aligned third holes 854 are provided through the connectionplate 812. The shape of each of the third holes 854 differs from the“first” shape of each of the first holes 834 and the “second” shape ofsecond holes 844. In this embodiment, the centerline of the linearlyaligned third holes 854 in row 850 is spaced approximately 1.0 inch fromthe centerline of linearly aligned second holes 844 in row 840.Likewise, the centerline of the linearly aligned third holes 854 in row852 is approximately 1.0 inch from the centerline of the linearlyaligned second holes 844 in row 842 and also approximately 1.0 inch fromthe centerline of the linearly aligned third holes 854 in row 850. Thethird holes 854 in this embodiment are round and sized to accommodatethe desired fasteners. In one embodiment, for example, the third holes854 are approximately 5/32 inches in diameter and may accommodate No.10-16 screws. However, other types and sizes of fasteners may beemployed.

In this embodiment, the first holes 834, second holes 844 and thirdholes 854 are further aligned to form a first column of linearly alignedholes designated as first column 860, a second column of linearlyaligned holes designated as second column 862, a third column oflinearly aligned holes designated as third column 864, a fourth columnof linearly aligned holes designated as fourth column 866 and a fifthcolumn of linearly holes designed as fifth column 868.

Each particular hole shape has a load capacity associated with it. Thatis, by filling all of the first holes 834 with appropriately sizedfasteners that correspond to those holes, a first predetermined loadcapacity for the connection may be attained. By filling all of thesecond holes 844 with appropriately sized fasteners that correspond tothose holes, a second predetermined load capacity for the connection maybe achieved. By filling all of the third holes 854 with appropriatelysized fasteners that correspond to those holes, a third load capacitymay be achieved for the connection. By filling only all of the first andsecond holes 834, 844 with appropriately sized fasteners correspondingto those holes, a fourth predetermined load capacity may be achieved. Byfilling only all of the first and third holes 834, 854 withappropriately sized fasteners corresponding to those holes, a fifthpredetermined load capacity may be achieved. By filling only all of thesecond and third holes 844, 854 with appropriately sized fastenerscorresponding to those holes, a sixth predetermined load capacity forthe connection may be achieved. By filling all of the first, second andthird holes 834, 844, 854 with corresponding fasteners, a seventhpredetermined load capacity for the connection may be achieved.

The following chart provides an example of the loading characteristicsthat may be achieved using conventional connectors: Framing 10 Screws 20Screws 30 Screws Gauge Framing Fy Jamb Header Jamb Header Jamb HeaderConnector (Mils) (ksi) Capacity Capacity Capacity Capacity CapacityCapacity H436 20 (33) 33 561 307 1121 507 1361 637 Using 18 (43) 33 832455 1361 753 1361 945 #12-16 16 (54) 33 832 455 1361 753 1361 945 Screws50 832 455 1361 753 1361 945 14 (68) 33 832 455 1361 753 1361 945 50 832455 1361 753 1361 945 12 (97) 33 832 455 1361 753 1361 945 50 832 4551361 753 1361 945 H546 20 (33) 33 561 307 1121 507 1682 637 Using 18(43) 33 832 455 1664 753 2496 945 #10-16 16 (54) 33 1172 641 2345 10612634 1332 Screws 50 1682 919 2634 1522 2634 1910 14 (68) 33 1655 9052634 1498 2634 1880 50 1682 919 2634 1522 2634 1910 12 (97) 33 1682 9192634 1522 2634 1910 50 1682 919 2634 1522 2634 1910 H686 20 (33) 33 630344 1260 570 1890 716 Using 18 (43) 33 935 511 1870 846 2805 1062 ¼″-1416 (54) 33 1318 720 2635 1193 3821 1497 Screws 50 1997 1091 3821 18073821 2268 14 (68) 33 1860 1017 3720 1684 3821 2113 50 2818 1541 38212551 3821 3201 12 (97) 33 2818 1541 3821 2551 3821 3201 50 2818 15413821 2551 3821 3201

The skilled artisan will appreciate that the unique and novel fastenerhole arrangement of the connection plate embodiment of the presentinvention may be adapted to assist the installer in quickly attainingthe desired load capacity when coupling a header 130 to a jamb stud 50.By locating the holes in the necessary locations and providing theinstaller with information indicating: (i) the type and size of fastenerassociated with each shape of hole and (ii) an indication of the loadcapacity attainable by employing fasteners through particular shapes ofholes, the installer will be able to quickly achieve a connection thatwill have the desired load capacity characteristics. It will be furtherappreciated that particular shapes and orientations of the fastenerholes depicted in FIG. 26 are merely illustrative of one embodiment ofthe connection plate of the present invention. The numbers, locationsand particular shapes of holes may vary with the size of the plateemployed and the load capacity required. For example, the rows of squareholes may be provided where the rows of round holes are located and therows of round holes may be provided where the rows of square holes arelocated, ect. Thus, the scope of protection afforded to the connectionplate of the present invention should not be limited to the particularshape and arrangements of holes depicted in FIGS. 26-28 and describedabove. A myriad of different shapes, sizes and arrangements of holes arecontemplated.

To aid in the quick positioning of the connection plate 812 such that itproperly spans between the jamb stud 50 and the header 130 and thefastener holes are oriented in desired positions to facilitate fasteningof the plate 812 in the desired position, a locator tab 890 is formed onthe lower parametrical edge 816 of the connection plate 812. In oneembodiment, the locator tab 890 is substantially planar andsubstantially rectangular in shape and protrudes outward from theconnection plate such that it is substantially perpendicular thereto.For example, the locator tab 890 may be approximately 2 inches long(distance “O”) and approximately 1.5 inches wide (distance “P”). For usein connection with conventional jamb stud assemblies, the locator tab890 may be located approximately 3.25 inches from the end of theconnection plate 812 (distance “Q”).

FIGS. 25 and 29, illustrate use of one embodiment of the connector 810of the present invention to connect a conventional header 130 to aconventional jamb stud 50. As can be seen in those Figures, theinstaller places the locator tab 890 under the header 130 and moves itinto abutting contact with the jamb stud 50. The locator tab 890 servesto position the connector 810 such that the first and second columns860, 862 of holes are aligned to permit fasteners 892 to be installedthrough the holes of those columns and into the jamb stud 50. Likewise,the columns 864, 866, 868 of holes are located to permit fastener to beinserted therethrough into the header 130. The reader will appreciatethat two connectors 810 may be employed to attach one end of the header130 to the corresponding jamb stud 50. Thus, four connectors 810 may beemployed to attach the ends of the header 130 to two spaced jamb studs50 to form a window, door or other opening. Such unique and novelarrangement of the connector 810 enables the connector 810 to be used oneither side and either end of the header for attachment purposes. Thisis can be a very useful advantage when compared with other types ofconnector arrangements employed to connector headers to jamb studs. Suchconnector arrangements require different connectors for connecting leftand right ends of the header to the jamb stud. This undesirable featurerequires the installer to have both types of connectors on hand duringthe construction process. Whereas, when using the connector 810 of thepresent invention, only one type of connector is required.

The connector 810 of the present invention may also be effectively usedin connection with header studs 220 of the type and constructiondescribed above. In particular and with reference to FIGS. 30 and 31, aheader assembly embodiment 1000 of the present invention is depicted foruse in connection with a conventional jamb stud 50. In this embodiment,header assembly 1000 includes a pair of header studs 220 that arearranged such that the first leg 228 of one header stud 220 is inabutting contact with the first leg 228 of the other header stud 220.Likewise, the second leg 230 of the one header stud 220 is in abuttingcontact with the second leg 230 of the other header stud 220 as shown inFIGS. 30 and 31.

A pair of connector plates 810 is used on each end of the headerassembly 1000 to attach one end of the header assembly 1000 to thecorresponding jamb stud 50. Fasteners 892 such as 10-16 screws, etc. areinserted through the holes in the connector plate 812 of the connectors810. FIGS. 30 and 31 illustrate use of fasteners 892 through all of theholes in the connector plate 812. The reader will appreciate that thenumber and types of fasteners 892 employed may vary depending upon theload capacity desired and the corresponding hole shapes that must befilled with a corresponding fastener 892. The locator tab 890, whenabutted against the jamb stud 50, serves to locate the columns 866 and868 of holes through the connector plate 812 along the jamb stud 50 forattachment of the plate 812 thereto. The header studs 220 in thisembodiment may or may not be attached to each other by other fasteners(screws) or by welding. In those embodiments wherein the header studs220 are not independently attached to each other, they are simplysandwiched together at their respective ends between the correspondingpairs of connectors 810.

FIGS. 32 and 33 illustrate the use of the connector plates 810 of thesubject invention in connection with an alternative header assembly 1100of the present invention which also employs a pair of header studs 220of the type and construction described above. In this embodiment, theweb 222 of one of the header studs 220 is in abutting contact with theweb 222 of the other header stud 220 as shown in FIG. 32. In oneembodiment, the webs 222 may be interconnected by fasteners such asscrews 892 or the like. See FIG. 33.

A pair of connector plates 810 is used on each end of the headerassembly 1100 to attach the header assembly 1100 to the correspondingjamb stud 50. Fasteners 892 such as 10-16 screws, etc. are insertedthrough the holes in the connector plate 812 of the connectors 810. FIG.32 illustrates use of fasteners 892 through all of the holes in theupper two rows 830, 840 of holes and the lower two rows 832, 842 ofholes in the connector plate 812. The reader will appreciate that thenumber and types of fasteners 892 employed may vary depending upon theload capacity desired and the corresponding hole shapes that must befilled with a corresponding fastener 892. The locator tab 890 whenabutted against the jamb stud 50 serves to locate the columns 866 and868 along the jamb stud 50 for attachment of the plate 812 thereto. Theheader studs 220 in this embodiment may or may not be attached to eachother by other fasteners (screws) or by welding. In those embodimentswherein the header studs 220 are not attached to each other, they aresimply sandwiched together at their respective ends between thecorresponding pairs of connectors 810.

FIGS. 34 and 35 illustrate the use of the connector plates 810 of thesubject invention in connection with an alternative header assembly 1200of the present invention which also employs a pair of header studs 220of the type and construction described above. In this embodiment, thefirst leg 228 and the second leg 230 of one of the header studs 22 arein abutting contact with the web 222 of the other header stud 220 asshown in FIGS. 34 and 35.

A pair of connector plates 810 is used on each end of the headerassembly 1200 to attach the header assembly 1200 to the correspondingjamb stud 50. Fasteners 892 such as 10-16 screws, etc. are insertedthrough the holes in the connector plate 812 of the connectors 810. FIG.35 illustrates use of fasteners 892 through all of the holes in theconnection plate 812 that is abutted against the web 222 of one of theheader studs 220. That Figure also illustrates fasteners 892 through allof the holes in the upper two rows 830, 840 of holes and the lower tworows 832, 842 of holes in the connector plate 812 that is abuttedagainst the first leg 228 and the second leg 230 of the other headerstud 220. The reader will appreciate that the number and types offasteners 892 employed may vary depending upon the load capacity desiredand the corresponding hole shapes that must be filled with acorresponding fastener 892. The locator tab 890, when abutted againstthe jamb stud 50, serves to locate the columns 866 and 868 along thejamb stud 50 for attachment of the plate 812 thereto. The header studs220 in this embodiment may or may not be attached to each other by otherfasteners (screws) or by welding. In those embodiments wherein theheader studs 220 are not attached to each other, they are simplysandwiched together at their respective ends between the correspondingpairs of connectors 810.

FIGS. 36 and 37 illustrate use of an embodiment of the connector plates810 of the present invention to connect an end of a header assembly 1000of the type and construction described above to a jamb stud 220′embodiment of the present invention. As can be seen in those Figures,the header assembly 1000 includes a pair of header studs 220 that arearranged such that the first leg 228 of one header stud 220 is inabutting contact with the first leg 228 of the other header stud 220.Likewise, the second leg 230 of the one header stud 220 is in abuttingcontact with the second leg 230 of the other header stud 220. As wasdescribed above, an embodiment of the jamb stud 220′ has a substantiallyplanar jamb stud web 222′, a first jamb stud flange 224′ and a secondjamb stud flange 226′ that protrude from the jamb stud web 222′. A firstjamb stud leg 228′ is attached or otherwise formed on the first jambstud flange 224′ and a second jamb stud leg 230′ is formed on orattached to the second jamb stud flange 226′. A first jamb stud return232′ is formed on the end of the first jamb stud leg 228′ and a secondjamb stud return 234′ is formed on the end of the second jamb stud leg230′.

A pair of connector plates 810 is used on each end of the headerassembly 1000 to attach one end of the header assembly 1000 to thecorresponding jamb stud 220′. Fasteners 892 such as 10-16 screws, etc.are inserted through the holes in the connector plate 812 of theconnectors 810. FIGS. 30 and 31 illustrate use of fasteners 892 throughall of the holes in the connector plate 812. The reader will appreciatethat the number and types of fasteners 892 employed may vary dependingupon the load capacity desired and the corresponding hole shapes thatmust be filled with a corresponding fastener 892. The locator tab 890when abutted against the web 222′ of the jamb stud 220′ serves to locatethe columns 866 and 868 of holes through the connector plate 812 alongone of the corresponding the flanges 224′, 226′ (whatever the case maybe) of the jamb stud 220′ for attachment of the plate 812 thereto. Theheader studs 220 in this embodiment may or may not be attached to eachother by other fasteners (screws) or by welding. In those embodimentswherein the header studs 220 are not attached to each other, they aresimply sandwiched together at their respective ends between thecorresponding pairs of connectors 810.

FIGS. 38 and 39 illustrate use of an embodiment of the connector plates810 of the present invention to connect an end of a header assembly 1100of the type and construction described above to a jamb stud 220′embodiment of the present invention. As can be seen in those Figures,the header assembly 1100 includes a pair of header studs 220 that arearranged such that the web 222 of one header stud 220 is in abuttingcontact with the web 222 of the other header stud 220. As was describedabove, an embodiment of the jamb stud 220′ has a substantially planarjamb stud web 222′, a first jamb stud flange 224′ and a second jamb studflange 226′ that protrude from the jamb stud web 222′. A first jamb studleg 228′ is attached or otherwise formed on the first jamb stud flange224′ and a second jamb stud leg 230′ is formed on or attached to thesecond jamb stud flange 226′. A first jamb stud return 232′ is formed onthe end of the first jamb stud leg 228′ and a second jamb stud return234′ is formed on the end of the second jamb stud leg 230′.

A pair of connector plates 810 is used on each end of the headerassembly 1100 to attach one end of the header assembly 1100 to thecorresponding jamb stud 220′. Fasteners 892 such as 10-16 screws, etc.are inserted through the holes in the connector plate 812 of theconnectors 810.

FIGS. 38 and 39 illustrate use of fasteners 892 through all of the holesin the upper two rows and lower two rows of holes in the connector plate812. The reader will appreciate that the number and types of fasteners892 employed may vary depending upon the load capacity desired and thecorresponding hole shapes that must be filled with a correspondingfastener 892. The locator tab 890 when abutted against the web 222′ ofthe jamb stud 220′ serves to locate the columns 866 and 868 of holesthrough the connector plate 812 along one of the corresponding theflanges 224′, 226′ (whatever the case may be) of the jamb stud 220′ forattachment of the plate 812 thereto. The header studs 220 in thisembodiment may or may not be attached to each other by other fasteners(screws) or by welding. In those embodiments wherein the header studs220 are not attached to each other, they are simply sandwiched togetherat their respective ends between the corresponding pairs of connectors810.

FIGS. 40 and 41 illustrate use of an embodiment of the connector plates810 of the present invention to connect an end of a header assembly 1200of the type and construction described above to a jamb stud 220′embodiment of the present invention. As can be seen in those Figures,the header assembly 1200 includes a pair of header studs 220 that arearranged such that the first leg 228 and the second leg 230 of oneheader stud is in abutting contact with the web 222 of the other headerstud 220. As was described above, an embodiment of the jamb stud 220′has a substantially planar jamb stud web 222′, a first jamb stud flange224′ and a second jamb stud flange 226′ that protrude from the jamb studweb 222′. A first jamb stud leg 228′ is attached or otherwise formed onthe first jamb stud flange 224′ and a second jamb stud leg 230′ isformed on or attached to the second jamb stud flange 226′. A first jambstud return 232′ is formed on the end of the first jamb stud leg 228′and a second jamb stud return 234′ is formed on the end of the secondjamb stud leg 230′.

A pair of connector plates 810 is used on each end of the headerassembly 1200 to attach one end of the header assembly 1200 to thecorresponding jamb stud 220′. Fasteners 892 such as 10-16 screws, etc.are inserted through the holes in the connector plate 812 of theconnectors 810.

FIG. 41 illustrates use of fasteners 892 through all of the holes in theconnection plate 812 that is abutted against the web 222 of one of theheader studs 220. That Figure also illustrates fasteners 892 through allof the holes in the upper two rows and lower two rows of holes in theconnector plate 812 that is abutted against the first leg 228 and thesecond leg 230 of the other header stud 220. The reader will appreciatethat the number and types of fasteners 892 employed may vary dependingupon the load capacity desired and the corresponding hole shapes thatmust be filled with a corresponding fastener 892. The locator tab 890when abutted against the web 222′ of the jamb stud 220′ serves to locatethe columns 866 and 868 of holes through the connector plate 812 alongone of the corresponding the flanges 224′, 226′ (whatever the case maybe) of the jamb stud 220′ for attachment of the plate 812 thereto. Theheader studs 220 in this embodiment may or may not be attached to eachother by other fasteners (screws) or by welding. In those embodimentswherein the header studs 220 are not attached to each other, they aresimply sandwiched together at their respective ends between thecorresponding pairs of connectors 810.

The reader will appreciate that a variety of other connectors could alsobe employed to couple the various header assemblies 1000, 1100, 1200described above to convention jamb stud assemblies 50 or to jamb studs220′ of the types described herein without departing from the spirit andscope of the present invention.

As can be appreciated from the foregoing description, the unique andnovel header assemblies and connection plates of the present inventionmay have a variety of advantages over prior header arrangements andconnectors. The unique and novel connector of the present inventioneliminates the need for “left” and “right” connectors for attachingheader assemblies to jamb studs or when connecting other types ofcomponents. In addition, the unique fastener hole arrangement employedin such connector plates enables the installer to easily attain thedesired load capacity for the connection. The reader will alsoappreciate the connectors of the subject invention may be employed withconventional headers and jamb studs. It will be further appreciated thatthe connectors of the present invention may also be used to connectwooden header arrangements to wood jamb studs or, if desired, to connecta metal header assembly to a wooden jamb stud or a wooden header to ametal jamb stud. The various embodiments of the subject inventiondepicted in FIGS. 30-41 may also be constructed utilizing studs 620 ofthe type and construction described above.

The present invention also addresses the problems associated withfabricating headers from metal or the like. The unique and novel headerassemblies of the present invention may be quickly assembled togetherwithout the need to employ several pieces of studs and track andfasteners to couple them together. In applications wherein it isdesirable to install insulation inside of the header assemblies, theinstaller should find it easier to install insulation in at least someof the header assemblies of the present invention when compared toinstalling insulation in prior header arrangements.

The invention which is intended to be protected is not to be construedas limited to the particular embodiments disclosed. The embodiments aretherefore to be regarded as illustrative rather than restrictive.Variations and changes may be made by others without departing from thespirit of the present invention. Accordingly, it is expressly intendedthat all such equivalents, variations and changes which fall within thespirit and scope of the present invention as defined in the claims beembraced thereby.

1. A header assembly comprising: a first header stud comprising: asubstantially planar first header web; a first header flange protrudingfrom said substantially planar first header web; a second header flangeprotruding from said substantially planar first header web and beingspaced from said first header flange; a first header leg protruding fromsaid first header flange and being substantially parallel to saidsubstantially planar first header web; a second header leg protrudingfrom said second header flange and being substantially parallel to saidsubstantially planar first header web and substantially coplanar withsaid first header leg; a first header return on an end of said firstheader leg; and a second header return on an end of said second headerleg; another header stud comprising: another substantially planar headerweb; another first header flange protruding from said anothersubstantially planar header web; another second header flange protrudingfrom said another substantially planar header web and being spaced fromsaid another first header flange; another first header leg protrudingfrom said another first header flange and being substantially parallelto said another substantially planar header web; another second headerleg protruding from said another second header flange and beingsubstantially parallel to said another substantially planar header weband substantially coplanar with said another first header leg, anotherfirst header return on another end of said another first header leg; andanother second header return on another end of said another secondheader leg, said another header stud retained in abutting contact withsaid first header stud to form a header assembly.
 2. The header assemblyof claim 1 wherein said first header leg abuts said another first headerleg and wherein said second header leg abuts said another second headerleg.
 3. The header assembly of claim 1 wherein said first header webabuts said another header web.
 4. The header assembly of claim 1 whereinsaid first and second header legs abut said another header web.
 5. Theheader assembly of claim 2 wherein said first header stud is welded tosaid another header stud.
 6. The header assembly of claim 3 wherein saidfirst header stud is welded to said second header stud.
 7. The headerassembly of claim 4 wherein said first header stud is welded to saidsecond header stud.
 8. The header assembly of claim 1 wherein at leastone of said first header stud and said another header stud has at leastone stiffener rib formed therein.
 9. The header assembly of claim 8wherein at least one said stiffener rib extends for an entire length ofat least one of said first header stud or said another header stud. 10.The header assembly of claim 8 wherein at least one said stiffener ribextends intermittently along an entire length of at least one of saidfirst header stud of said another header stud.
 11. The header assemblyof claim 1 further comprising at least one opening through at least oneof said first header stud and said another header stud.
 12. The headerassembly of claim 11 wherein at least one said opening has a perimeterand further comprising a flange formed around said perimeter.
 13. Aconnector for coupling an end of a header assembly to a jamb studoriented adjacent thereto, the connector comprising: a substantiallyplanar connection plate sized to span between the end of the headerassembly and the jamb stud; a plurality of first fastener holes throughsaid connection plate wherein said first fastener holes each have afirst shape; a plurality of second fastener holes through saidconnection plate, wherein each of said second fastener holes has asecond shape that differs from said first shape; and a locator tabprotruding from said substantially planar connection plate such thatwhen the locator tab is brought into abutting contact with the jambstud, a portion of the end of the header assembly is coextensive with afirst portion of the connection plate and a portion of the jamb stud iscoextensive with a second portion of the connection plate such that atleast one first fastener hole and at least one second fastener hole areeach adjacent to the coextensive end of the header assembly and at leastone other first fastener hole and at least one other second fastenerhole are adjacent to the coextensive portion of the jamb stud.
 14. Theconnector of claim 13 wherein said locator tab protrudes from aparametric edge of the connection plate.
 15. The connector of claim 13further comprising at least one other plurality of fastener holesthrough said connection plate, each said another plurality of fastenerholes having another shape that differs from said first and secondshapes.
 16. The connector of claim 13 further comprising a plurality ofthird fastener holes having a third shape that differs from said firstand second shapes.
 17. The connector of claim 16 wherein said firstholes are substantially square-shaped and wherein said second holes aresubstantially triangular-shaped and wherein said third holes aresubstantially round.
 18. The connector of claim 13 wherein said firstholes are linearly aligned in at least one first row and wherein saidsecond holes are linearly aligned in at least one second row.
 19. Theconnector of claim 16 wherein said first holes are linearly aligned inat least one first row and wherein said second holes are linearlyaligned in at least one second row and wherein said third holes arelinearly aligned in at least one third row.
 20. The connector of claim13 wherein said first holes are associated with a first fastener suchthat when corresponding first fasteners are installed through all ofsaid first holes adjacent to the coextensive end of the header assemblyand other first fasteners are installed through all of said first holesadjacent to the portion of the jamb stud, the connector has a first loadcapacity.
 21. The connector of claim 13 wherein said second holes areassociated with a second fastener such that when corresponding secondfasteners are installed through all of said second holes adjacent to thecoextensive end of the header assembly and other second holes areinstalled through all of said second holes adjacent to the portion ofthe jamb stud, the connector has a second load capacity.
 22. Theconnector of claim 21 wherein, when corresponding first fasteners areinstalled through all of said first holes adjacent to the coextensiveend of the header assembly and other first fasteners are installedthrough all of said first holes adjacent to the portion of the jamb studand when corresponding second fasteners are installed through all ofsaid second holes adjacent to the coextensive end of the header assemblyand other second holes are installed through all of said second holesadjacent to the portion of the jamb stud, the connector has a third loadcapacity.
 23. The connector of claim 16 wherein each of said firstfastener holes has a first fastener associated therewith and whereineach of said second fastener holes has a second fastener associatedtherewith and wherein each of said third fastener holes has a thirdfastener associated therewith and wherein when corresponding firstfasteners are installed through all of said first holes adjacent to thecoextensive end of the header assembly and other first fasteners areinstalled through all of said first holes adjacent to the portion of thejamb stud and when corresponding second fasteners are installed throughall of said second holes adjacent to the coextensive end of the headerassembly and other second holes are installed through all of said secondholes adjacent to the portion of the jamb stud, the connector has athird load capacity.
 24. The connector of claim 23 wherein, whencorresponding first fasteners are installed through all of said firstholes adjacent to the coextensive end of the header assembly and otherfirst fasteners are installed through all of said first holes adjacentto the portion of the jamb stud and when corresponding third fastenersare installed through all of said third holes adjacent to thecoextensive end of the header assembly and other third holes areinstalled through all of said third holes adjacent to the portion of thejamb stud, the connector has a fourth load capacity.
 25. The connectorof claim 24 wherein, when corresponding second fasteners are installedthrough all of said second holes adjacent to the coextensive end of theheader assembly and other second fasteners are installed through all ofsaid second holes adjacent to the portion of the jamb stud and whencorresponding third fasteners are installed through all of said thirdholes adjacent to the coextensive end of the header assembly and otherthird holes are installed through all of said third holes adjacent tothe portion of the jamb stud, the connector has a fifth load capacity.26. The connector of claim 19 wherein said first, second and third holesare also arranged to form a plurality of columns of holes through saidconnection plate such that at least one said first hole, at least onesaid second hole and at least one said third hole are in at least onecommon said column of holes.
 27. The connector of claim 17 wherein saidconnector plate comprises: at least two first rows of said first holesthrough said connection plate; at least two second rows of said secondholes through said connection plate; and at least two third rows of saidthird holes through said connection plate.
 28. A header and jamb studarrangement, comprising: a pair of jamb studs spaced from each other; aheader assembly extending between said pair of spaced jamb studs todefine an opening between the jamb studs, said header assemblycomprising: a first header stud comprising: a substantially planar firstheader web; a first header flange protruding from said substantiallyplanar first header web; a second header flange protruding from saidsubstantially planar first header web and being spaced from said firstheader flange; a first header leg protruding from said first headerflange and being substantially parallel to said substantially planarfirst header web; a second header leg protruding from said second headerflange and being substantially parallel to said substantially planarfirst header web and substantially coplanar with said first header leg;a first header return on an end of said first header leg; and a secondheader return on an end of said second header leg; another header studcomprising: another substantially planar header web; another firstheader flange protruding from said another substantially planar headerweb; another second header flange protruding from said anothersubstantially planar header web and being spaced from said another firstheader flange; another first header leg protruding from said anotherfirst header flange and being substantially parallel to said anothersubstantially planar header web; another second header leg protrudingfrom said another second header flange and being substantially parallelto said another substantially planar header web and substantiallycoplanar with said another first header leg, another first header returnon another end of said another first header leg; and another secondheader return on another end of said another second header leg, saidanother header stud in abutting contact with said first header stud toform a header assembly; a first connector arrangement for connecting oneend of said header assembly to one of said jamb studs; and a secondconnector arrangement for connecting another end of said header assemblyto the other one of said jamb studs.
 29. The header and jamb studarrangement of claim 28 wherein said first header stud and said secondheader stud are fastened together independently of said first and secondconnector arrangements.
 30. The header and jamb stud arrangement ofclaim 28 wherein said first connector arrangement comprises: a pair offirst connectors wherein at least one said first connector comprises: asubstantially planar first connection plate sized to span between theend of the header assembly and the jamb stud; a plurality of firstfastener holes through said first connection plate wherein said firstfastener holes each have a first shape; a plurality of second fastenerholes through said first connection plate, wherein each of said secondfastener holes has a second shape that differs from said first shape;and a first locator tab protruding from said substantially planar firstconnection plate such that when the locator tab is brought into abuttingcontact with the jamb stud, a portion of the end of the header assemblyis coextensive with a first portion of the first connection plate and aportion of the jamb stud is coextensive with a second portion of thefirst connection plate such that it least one first fastener hole and atleast one second fastener hole are each adjacent to the coextensive endof the header assembly and at least one other first fastener hole and atleast one other second fastener hole are adjacent to the coextensiveportion of the jamb stud.
 31. The header and jamb stud arrangement ofclaim 30 wherein at least one of said first connection plates has atleast one other plurality of fastener holes through said connectionplate, each said another plurality of fastener holes having anothershape that differs from said first and second shapes.
 32. The header andjamb stud arrangement of claim 30 wherein said second connectorarrangement comprises: a pair of second connectors wherein at least onesaid second connector comprises: a substantially planar secondconnection plate sized to span between another end of the headerassembly and the other jamb stud; a plurality of primary fastener holesthrough said second connection plate wherein said primary fastener holeseach have a primary shape; a plurality of secondary fastener holesthrough said second connection plate, wherein each of said secondaryfastener holes has a secondary shape that differs from said primaryshape; and a second locator tab protruding from said substantiallyplanar second connection plate such that when the second locator tab isbrought into abutting contact with the other jamb stud, a portion of theother end of the header assembly is coextensive with a primary portionof the second connection plate and a portion of the other jamb stud iscoextensive with a secondary portion of the second connection plate suchthat at least one primary fastener hole and at least one secondaryfastener hole are each adjacent to the coextensive other end of theheader assembly and at least one other primary fastener hole and atleast one other secondary fastener hole are adjacent to the coextensiveportion of the other jamb stud.
 33. The header and jamb stud arrangementof claim 32 wherein at least one of said second connection plates has atleast one other plurality of fastener holes through said secondconnection plate, each said another plurality of fastener holes havinganother shape that differs from said primary and secondary shapes. 34.The header and jamb stud arrangement of claim 28 wherein at least one ofsaid jamb studs comprise: a substantially planar jamb stud web; a firstjamb stud flange protruding from said substantially planar jamb studweb; a second jamb stud flange protruding from said substantially planarjamb stud web and being spaced from said first jam stud flange; a firstjamb stud leg protruding from said first jamb stud flange and beingsubstantially parallel to said substantially planar jamb stud web; asecond jamb stud leg protruding from said second jamb stud flange andbeing substantially parallel to said substantially planar jamb stud web;a first jamb stud return on an end of said first jamb stud leg; and asecond jamb stud return on an end of said second jamb stud leg.
 35. Theheader and jamb stud arrangement of claim 28 wherein at least one ofsaid jamb studs comprise: a first stud having a first web and a pair offirst flanges protruding therefrom; a second piece of track having asecond web and pair of flanges protruding therefrom, said first studbeing oriented relative to said second piece of track such that saidfirst flanges are received between said second flanges; and a third studhaving a third web and a pair of third flanges protruding therefrom;said third web in abutting contact with said second web.
 36. The headerand jamb stud arrangement of claim 28 wherein said first header legabuts said another first header leg and wherein said second header legabuts said another second header leg.
 37. The header and jamb studarrangement of claim 28 wherein said first header web abuts said anotherfirst header web.
 38. The header and jamb stud arrangement of claim 28wherein said first and second header legs abut said another header web.39. A header and jamb stud arrangement comprising: a pair of jamb studsspaced from each other; a header assembly extending between said pair ofspaced jamb studs to define an opening between the jamb studs; a firstconnector arrangement for connecting one end of said header assembly toone of said jamb studs, said first connector arrangement comprises apair of first connectors wherein at least one said first connectorcomprises: a substantially planar first connection plate sized to spanbetween the end of the header assembly and the jamb stud; a plurality offirst fastener holes through said first connection plate wherein saidfirst fastener holes each have a first shape; a plurality of secondfastener holes through said first connection plate, wherein each of saidsecond fastener holes has a second shape that differs from said firstshape; and a first locator tab protruding from said substantially planarfirst connection plate such that when the locator tab is brought intoabutting contact with the jamb stud, a portion of the end of the headerassembly is coextensive with a first portion of the first connectionplate and a portion of the jamb stud is coextensive with a secondportion of the first connection plate such that it least one firstfastener hole and at least one second fastener hole are each adjacent tothe coextensive end of the header assembly and at least one other firstfastener hole and at least one other second fastener hole are adjacentto the coextensive portion of the jamb stud; and a second connectorarrangement for connecting another end of said header assembly to theother one of said jamb studs.
 40. The header and jamb stud arrangementof claim 39 wherein at least one of said connection plates has at leastone other plurality of fastener holes through said connection plate,each said another plurality of fastener holes having another shape thatdiffers from said first and second shapes.
 41. The header and jamb studarrangement of claim 39 wherein said second connector arrangementcomprises: a pair of second connectors wherein at least one said secondconnector comprises: a substantially planar second connection platesized to span between another end of the header assembly and the otherjamb stud; a plurality of primary fastener holes through said secondconnection plate wherein said primary fastener holes each have a primaryshape; a plurality of secondary fastener holes through said secondconnection plate, wherein each of said secondary fastener holes has asecondary shape that differs from said primary shape; and a secondlocator tab protruding from said substantially planar second connectionplate such that when the second locator tab is brought into abuttingcontact with the other jamb stud, a portion of the other end of theheader assembly is coextensive with a primary portion of the secondconnection plate and a portion of the other jamb stud is coextensivewith a secondary portion of the second connection plate such that atleast one primary fastener hole and at least one secondary fastener holeare each adjacent to the coextensive other end of the header assemblyand at least one other primary fastener hole and at least one othersecondary fastener hole are adjacent to the coextensive portion of theother jamb stud.
 42. The header and jamb stud arrangement of claim 41wherein at least one of said second connection plates has at least oneother plurality of fastener holes through said second connection plate,each said another plurality of fastener holes having another shape thatdiffers from said primary and secondary shapes.
 43. The header and jambstud arrangement of claim 39 wherein at least one of said jamb studscomprise: a substantially planar jamb stud web; a first jamb stud flangeprotruding from said substantially planar jamb stud web; a second jambstud flange protruding from said substantially planar jamb stud web andbeing spaced from said first jam stud flange; a first jamb stud legprotruding from said first jamb stud flange and being substantiallyparallel to said substantially planar jamb stud web; a second jamb studleg protruding from said second jamb stud flange and being substantiallyparallel to said substantially planar jamb stud web; a first jamb studreturn on an end of said first jamb stud leg; and a second jamb studreturn on an end of said second jamb stud leg.
 44. The header and jambstud arrangement of claim 39 wherein at least one of said jamb studscomprise: a first stud having a first web and a pair of first flangesprotruding therefrom; a second piece of track having a second web andpair of flanges protruding therefrom, said first stud being orientedrelative to said second piece of track such that said first flanges arereceived between said second flanges; and a third stud having a thirdweb and a pair of third flanges protruding therefrom; said third web inabutting contact with said second web.
 45. The header and jamb studarrangement of claim 39 wherein said header assembly comprises a pair ofC-shaped studs retained in spaced apart relationship between upper andlower track members.